Wall construction



June 12, 1962 E. F. HAUER WALL CONSTRUCTION 3 Sheets-Sheet 1 Filed Aug.6, 1958 'IN VEN TOR.

E rw/fl Franz Hauer BY (542 W June 12, 1962 HAUER 3,038,278

WALL CONSTRUCTION Filed Aug. 6, 1958 3 Sheets-Sheet 2 F/q. /6 INVENTOR.

Emu/n Franz Hauer June 1962 E. F. HAUER 38, 78

WALL CONSTRUCTION Filed Aug. 6, 1958 3 Sheets-Sheet 3 INVENTOR. Emu/r1Franz Haaer 2% a /Zm United States Patent Ofifice 3,038,278 PatentedJune 12, 1962 3,038,278 WALL CONSTRUCTIGN Erwin Franz Hauer,Vienna-Liesing, Austria (Star 67 Num. 142, Col. Prado Gral Anaya, Mexico(Iity 13, Mexico) Filed Aug. 6, 1958, Ser. No. 753,446 6 Claims. (Cl.50- 262) The present invention relates generally to an architecturalconstruction and is more particularly concerned with the provision of anovel and improved wall or surface construction.

A primary object of the instant invention is the provision of astructural assembly or system which can be used either as a horizontalspanning element or as a vertical wall.

Another important object of my invention is the provision of astructural assembly which provides highly effective fenestration whereindirect or diffused light is desired.

A further object of this invention is the provision of a wallconstruction wherein the structural or strength-imparting components areintegrated with an enclosing membrane or skin to provide a highlyeffective unit possessing a high degree of structural strength, while atthe same time utilizing a reduced amount of construction material,particularly as opposed to the prior art constructions wherein a givenwall generally consists of strengthimparting trusses in combination withseparate curtain walls or roof skin, the latter elements functioning toprovide the enclosing medium.

Another object of my invention is the provision of a wall constructionwhich may be manufactured by the fabrication of similar or identicalmodular units, it being possible to fabricate the completed wall eitheron location or beforehand.

Still another object of my invention is the provision of an integratedstructural and enclosing wall which possesses great strength Whileutilizing a relatively small amount of material, which has a reduceddead load, which diffuses light in a highly effective fashion and whichat the same time provides a construction of highly attractive andpleasing appearance.

Other objects, features and advantages of the invention will becomeapparent as the description thereof proceeds when considered inconnection with the accompanying illustrative drawings.

In the drawings which illustrate the best mode presently contemplated byme for carrying out my invention:

FIG. 1 is a diagrammatic view of a wall section embodying the preferredform of my invention;

FIG. 2 is a perspective view, on an enlarged scale, of a modular unitthat may be used in the manufacture of the instant invention;

FIG. 3 is a fragmentary section taken on line 3-3 of FIG. 2;

FIG. 4 is a fragmentary section taken on line 44 of FIG. 2;

FIG. 5 is a perspective view, on an enlarged scale, of a frame whichillustrates the geometrical configuration of the individual modularunits;

FIG. 6 is a perspective view, on an enlarged scale, illustrating onemethod of manufacturing the individual modular units;

FIGS. 7 through 12 are fragmentary sectional views, on an enlargedscale, illustrating various structural connections between adjacentmodular units constructed of concrete or shotcrete;

FIG. 13 is a fragmentary perspective view, on an enlarged scale,illustrating a structural arrangement and connection which may be usedwhere the modular units are of sheet metal;

FIG. 14 is a perspective view of a slightly modified wall construction;

FIG. 15 is a perspective View, on an enlarged scale, illustrating one ofthe individual modular units which may be utilized in the manufacture ofthe wall illustrated in FIG. 14;

FIG. 16 is a perspective view, on an enlarged scale, of a frame whichillustrates the configuration of the modular unit disclosed in FIG. 15

FIG. 17 is an exploded diagrammatic view of the wall section shown inFIG. 1; and

FIG. 18 is an exploded perspective view of the wall section shown inFIG. 14.

it has been found desirable to provide a structural wall consisting of acontinuous membrane. Thus, the web conventionally used in trusses toresist shear and to unify the flanges is replaced by an integratedsurface which makes the application of separate curtain walls for roofskin unnecessary. By combining the strength-imparting structure and theenclosing medium into one, numerous advantages are obtained, such asreduction in dead load, saving in material, and the integration ofarchitecture and structure whereby a unique and attractive appearancemay be achieved. In addition, as will hereinafter become apparent,symmetrically positioned openings are inherently present in the instantstructural assembly whereby effective fenestration and diffusion oflight is obtained.

It will be understood that the term wall construction as used herein isto be broadly construed, and it covers horizontal and angularly disposedsurfaces as well as vertical walls.

Referring now to the drawings, and more particularly to FIG. 1 thereof,there is shOWn a section of a wall constructed in accordance with theinstant invention, generally designated at 10. As will be noted, wall 10comprises a plurality of identically curved portions, one of which isillustrated at 12, note FIG. 2. In most instances the wall 10 is made upof a plurality of individual modular units 12 integrated in a mannerhereinafter to be described. In some cases, however, the wall 10 may beintegrally constructed rather than fabricated from individual modularunits, but in order to understand the basic concepts and characteristicsof wall 10, it is necessary to analyze the configuration of one of thecurved portions which make up the completed wall, and hence the modularunit 12 will now be described in detail.

Referring to FIGS. 5 and 6, it will be seen that the peripheral edge ofone of the modular units 12 defines a pair of parallel, equi-lengthchords 14 and 16, each of which has at its opposite extremitiesperpendicularly eX- tending struts 18 and 20. The struts 18 and 20 allextend in the same direction from the plane defined by chords 14 and 16and are of equal length. Adjacent struts 18 and 20 are connected attheir free extremity by cross bars 22, and the configuration defined bychords 14, 16, struts 18, 20, and cross bars 22, represents the shape ofthe periphery of each modular unit 12. The modular unit itself actuallycomprises a membrane 24 which represents the minimum surface capable ofspanning the peripheral edge configuration just described.

The membrane 24 may be constructed by a variety of manufacturingtechniques, hereinafter to be more fully described, and it will beunderstood that said membrane may be of any suitable structuralmaterial, such as metallic sheet, cast concrete, shotcrete (sprayedconcrete), structural plastic or plaster. As will be readily seen,particularly in FIGS. 2 and 6, the membrane 24 is characterized by adouble or compound curvature, which curvature closely approximates ahyperbolic paraboloid. Actually, the minimal surface spanning theperipheral edge oonfiguration illustrated in FIGS. 5 and 6 willautomatically assume this desired compound curvature, and as evidence ofthe fact that membrane 24 closely approximates a hyperbolic paraboloid,lines 26 (FIG. 5) joining the mid points of chords 14 and 16 with themid points of cross bars 22 to provide a diamond-like configuration willautomatically be straight lines. The portion of membrane 24 which isenclosed by imaginary lines 26 actually is a true hyperbolic paraboloid,and while the four corner portions of membrane 24 (the portions outsidethe diamond defined by imaginary lines 26) are not actually truehyperbolic paraboloids, they retain the double curvature which is theessential and basic characteristic of such a configuration. Theimportance of the foregoing is that it is a well-known structural factthat a curved surface in the form of a hyperbolic paraboloid possessesmaximum strength for a given weight and material since any stresses orstrains imparted to such a curved surface will be equally distributed,and there will be no localized build-up of stresses and strains such ascauses fatigue failure of truss systems and the like. Thus, the modularunit 12 with its highly specific curved membrane 24 represents one ofthe basic and salient concepts of the instant invention.

When integrating the modular units 12 to provide wall 10, the adjacentunits are reversely positioned with respect to each other, as shown mostclearly in FIG. 1. Thus, if unit 12a is positioned in the mannerillustrated, then adjacent unit 12b extends in the opposite direction,as will be clearly seen, while unit 12c assumes the same relativeposition as unit 12a. It will therefore be seen that the parallel chordsof the various units cooperate to define two planes parallelly spacedfrom each other and representing the inner and outer surfaces of thecompleted wall. At the same time, the cross bars 22 define a third planelocated intermediate the two aforesaid planes and also parallellydisposed with respect thereto. Actually, any single modular unit, suchas unit 12d, for example, is surrounded on its four sides with unitsextending in the opposite direction. When the various modular units 12are integrated in the manner aforesaid to provide the completed wall 10,aligned openings 28 will automatically be established, and since saidopenings extend in a plane substantially perpendicular to the generalplane of the overall wall, it follows that light passing through thewall will be well diffused, said diffusion being further enhanced by thecurvature of the membranes 24. It will be understood that the openings28 may be covered by suitable glass panels or the like if it is desiredto provide a complete and air-tight enclosure.

Where the individual modular units 12 are constructed of cast concrete,plaster or the like, numerous structural techniques may be employed forintegrating and joining abutting units, it being apparent that adjacentunits will make abutting engagement along their edges 18, 20 and 22.FIGS. 7 through 12 illustrate some of these various techniques and willnow be described. In FIG. 7 the abutting membranes 24 are provided withoutwardly extending metallic frames or bars 30 which are brought intoengagement with each other and then are welded such as at 32. Theconnection may then be filled in with concrete as at 34 to provide acontinuous flush surface.

In FIG. 8 the abutting membranes are provided at their edge portion withoppositely disposed metallic channels 36 secured to the membranes by anysuitable means, such as by having integral extensions imbedded thereinas at 38. The channels 36 receive therein a metallic spline or bar 40and then bolts 42 extend thereacross to integrate the structure.

In FIG. 9 the abutting membranes are provided at their edge portionswith imbedded T bars 44 making face-toface contact with each other asshown. The fiat surfaces of the T bars are then secured to each other inany desirable way, such as by bolts 46 or the like. The connection isthen filled in as at 48 to provide a flush, continuous surface. In FIG.10 the membrane edges are provided with imbedded metallic L-channels 59which receive therein a metallic spline or bar 52. The L-channels arethen integrated by means of a cross bolt 54.

In FIG. 11 the abutting edges are provided with imbedded metallicextensions 56 which overlie each other and are then bolted together asat 58. In FIG. 12 the abutting edges are provided with imbedded wiremesh 60 which overlaps and is then filled in with concrete or shotcreteas at 62 to provide a continuous, flush surface.

In order to further strengthen the completed wall 10 where the latter isformed by the integration of a plurality of cast concrete modular unitsas described supra, the individual modular units are cast withperipheral channels 64 as shown clearly in FIGS. 2 through 4. Elongatedmetallic strengthening rods (not shown) may then be positioned in saidaligned channels to enhance the rigidity and shear resistance of wall10.

Referring to FIG. 13, a connection is shown wherein the individualmodular units are constructed of sheet metal 56. In such a situation,the abutting edges of adjacent units are overlapped as at 68 and thensecured by any desirable means, such as rivets 70, spot welding or thelike. In order to strengthen the completed wall, I-beams 72 are securedto the aligned chord edges of adjacent modular units, as by rivets 74.It will be understood that the beams 72 extend completely across thecompleted wall 10, and, viewing FIG. 1, said beams would extend alongthe lines indicated by reference character 76.

In some instances, it is desirable to construct the wall 19 on site asopposed to fabrication of the wall from modular units as aforedescribed. In such a situation, a truss network comprising chords 14 and16, struts 18 and 20, and cross bars 22, is constructed and then wiremesh such as shown at 78 in FIG. 6 is secured to the framework toprovide a foundation for the continuous wall surface. Shotcrete is thensprayed on to the wire mesh, thereby forming the completed wall.

In FIGS. 14 through 16 a slightly modified form of the instant inventionis disclosed, the completed wall 86 being constructed by the integrationof identical modular units 82. Although membrane 84 of modular unit 32is somewhat similar to the aforedescribed membrane 24, it does differ incertain respects. First of all, membrane 84 is the minimum surfacecovering the configuration illustrated in FIG. 16, said configurationcomprising parallel chords 86, struts 88 and cross bars 90, all similarto the configuration which defines the aforediscussed membranes 24, butfurther including an additional chord 92 joining the mid points of crossbars 90. In addition, membrane 84 is thickened at its corner portions asat 94 and the chord edges of said membrane curve outwardly as at 96rather than having the straight edges which characterize membrane 24. Itwill be understood that the curved extensions 96 are primarily forshading purposes, and, in fact, all of the differences which exist inmodular unit 82 over the preferred unit 12 are for reasons of appearanceand light effect. As will be noted, each of the units 82 is providedwith end channels 98 which align to provide a single channel 100 whenthe units are integrated to form a complete wall, as shown most clearlyin FIG. 14. The units 82 are further provided with elongated bores 102which extend in a direction transverse to that of channels 98, it beingunderstood that said bores also align with those of adjacent units whensaid units are integrated. Thus, the channels 98 and bores 102 providemeans whereby wall may be strengthened and integrated, and morespecifically, elongated strengthening rods (not shown) are inserted insaid channels and bores to integrate adjacent units and also to impartgreater rigidity and shear resistance to the completed wall.

It will be understood that the frame illustrated in FIG. 16 has beenshown primarily as a means for defining and describing the configurationof modular unit 82. It is completely optional as to whether a physicalframe of this configuration be incorporated in each modular unit,

and in most cases such a frame would not be utilized. If for any reason,such as strengthening purposes, it is desired to actually imbed a framein this configuration in the modular unit, it would be positionedtherein the manner indicated in FIG. 18.

While there is shown and described herein certain specific structureembodying the invention, it will be manifest to those skilled in the artthat various modifications and rearrangements of the parts may be madewithout departing from the spirit and scope of the underlying inventiveconcept and that the same is not limited to the particular forms hereinshown and described except in so far as indicated by the scope of theappended claims.

I claim:

1. A wall construction comprising a plurality of identical modularunits, each of said units comprising a curved portion, the peripheraledge of which defines a configuration equal to that which would beestablished by a pair of equi-length, parallel chords, equi-lengthstruts extending one from each extremity of said chords in the samedirection from the plane defined by said chords and perpendicularthereto, and bars bridging. the struts of one chord with the adjacentstruts of the other chord at the free extremities of said struts, andmeans connecting said modular units to each other so as to providealigned horizontal and vertical rows, each unit being reverselypositioned with respect to its two contiguous horizontally aligned unitsand its two contiguous vertically aligned units, the adjacent bridgingbar edges of adjacent vertical units and the adjacent strut edges ofdiagonally adjacent units being in engagement with each other, each ofsaid curved portions representing the minimum surface capable ofcompletely spanning the configuration defined by the peripheral edge ofeach unit.

2. A wall construction comprising an undulating, rigid wall having aplurality of identical curved portions, each of said curved portionsrepresenting the minimum surface capable of spanning a configurationequal to that which would be established by a pair of equi-length,parallel chords, equi-length struts extending one from each extremity ofsaid chords in the same direction from the plane defined by said chordsand perpendicular thereto, and bars bridging the struts of one chordwith the adjacent struts of the other chord at the free extremities ofsaid struts, said curved portions being arranged in aligned horizontaland vertical rows, each portion being reversely positioned with respectto its two contiguous horizontally aligned portions and its twocontiguous vertically aligned portions, the adjacent bridging bar edgesof adjacent vertical portions and the adjacent strut edges of diagonallyadjacent portions merging with each other, the reverse positioning ofadjacent horizontal portions automatically providing a plurality ofsymmetrically arranged and staggered openings in said wall, whichopenings extend in a plane substantially perpendicular to the plane inwhich said wall extends.

3. A modular unit for use in the construction of a self-suppo=rtingwall, said unit comprising a rigid, curved portion, the peripheral edgeof which defines a configuration equal to that which would beestablished by a pair of equi-length, parallel chords, equi-lengthstruts extending one from each extremity of said chords in the samedirection 'from the plane defined by said chords and perpendicularthereto, and bars bridging the struts of one chord with the adjacentstruts of the other chord at the free extremities of said struts, saidcurved portion representing the minimum sunface capable of completelyspanning the configuration defined by of said unit.

4. A wall construction comprising a plurality of identical modularunits, each of said units comprising a curved portion which representsthe minimum surface capable of completely spanning a configuration equalto that which would be established by a pair of equi-lengtb, parallelchords, equi-length struts extending one from each extremity of saidchords in the same direction from the plane defined by said chords andperpendicular thereto, and bars bridging the struts of one chord withthe adjacent struts of the other chord at the free extremities of saidstruts, and further comprising a third chord interconnecting themidpoints of said bridging bars, and means connecting said modular unitsto each other so as to provide aligned horizontal and vertical rows,each unit being reversely positioned with respect to its two contiguoushorizontally aligned units and its two contiguous vertically alignedunits, the adjacent bridging bar edges of adjacent vertical units andthe adjacent strut edges of diagonally adjacent units being inengagement with each other.

5. A wall construction comprising an undulating, rigid wall having aplurality of identical curved portions, each of said curved portionsrepresenting the minimum surface capable of spanning a configurationequal to that which would be established by a pair of equi-length,parallel chords, equi-length struts extending one from each extremity ofsaid chords in the same direction from the plane defined by said chordsand perpendicular thereto, and bars bridging the struts of one chordwith the adjacent struts of the other chord at the free extremities ofsaid struts, and further comprising a third chord interconnecting themidpoints of said bridging bars, said curved portions being arranged inaligned horizontal and vertical rows, each portion being reverselypositioned with respect to its two contiguous horizontally alignedportions and its two contiguous vertically aligned portions, theadjacent bridging bar edges of adjacent vertical portions and theadjacent strut edges of diagonally adjacent portions merging with eachother, the reverse positioning of adjacent horizontal portionsautomatically providing a plurality of symmetrically arranged andstaggered openings in said wall, which openings extend in a planesubstantially perpendicular to the plane in which said wall extends.

6. A modular unit for use in the construction of a selfsupporting wall,said unit comprising a rigid curved portion which represents the minimumsurface capable of completely spanning a configuration equal to thatwhich would be established by a pair of equi-leng-th, parallel chords,equi-length struts extending one from each extremity of said chords inthe same direction from the plane defined by said chords andperpendicular thereto, and bars bridging the struts of one chord withthe adjacent struts of the other chord at the free extremities of saidstruts, and further comprising a third chord interconnecting themidpoints of said bridging bars.

the peripheral edge References (Iited in the file of this patent UNITEDSTATES PATENTS 1,154,254 Lachman Sept. 21, 1915 2,436,543 Blaski Feb.24, 1948 FOREIGN PATENTS 991.704 France June 27, 1951

